Sea Tel Coastal User manual

Field Service Procedure – Replacement PCU Kit, Coastal

Page1of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

1. BriefSummary:
TroubleshootingdocumentfordiagnosingafaultwithandreplacingthePCUassemblyonthecoastalseriesantennas.
2. Checklist:

Initialization
RateSensorOutputs
RuntheBuilt‐InTest(BIT)
3. TheoryofOperation:
TheCoastalseriesaretwoaxisantennas(elevationandazimuth)withamotorizedpolarizationassemblytokeepthe
LNBinthecorrectreceptionpositionunderdynamicconditions.ThePCUassemblyhousesamotherboardPCBfor
stabilizationandmotordriveandaDVBreceiverfortrackingtheRFsignal.
ThePCUmotherboardisresponsibleforthestabilizationoftheantenna,housingafluidfilledtiltsensorwhichactsas
thehorizonreferenceforelevationandpolaxisand3ratesensorsforstabilizationfortheazimuth,elevationpolaxis.
WhenmotionisdetectedbytherelevantratesensorthePCUmotherboardwillissuethedrivethemovetheaxisthe
oppositeamountmaintainstabilization.
Nogyroconnectionisintegratedinthesystem,whensearchingtheantennatargetsinelevationbasedonthevessels
GPSpositionanddesiredsatellite,theazimuthaxisthensweepsandsearchesforsignalabovethreshold.OncetheNID
forthedesiredsatellitehasbeendecodedtrackingwillbeenabled.
TheDVBreceiverinthePCUtakesafeeddirectlyfromtheLNBtoreceivethesatellitesignalandwillalsodecodethe
NID(NetworkIdentity)fromthecarriertheantennaistracking,astheoutputofthereceiverispassedtothemulti‐
switch.
4. Initialization:
Verifytheinitializationofthepedestal:
1. PowercycletheDACPcontrolpanel(thisprovidesthe12VDCtopowerthepedestalsPCU).
2. Thecontrolpanelwillthendisplaythefollowingsoftwareversions:DACP,antennamodelpresetinthePCU,
PCUsoftwareversion,DVBsoftwareversion,antennaserialnumberandelevationencoderengagement(if
applicable).
3. “Initializing”willthenbedisplayedwithaflashing“0”untiltheGPSpositionhavebeenacquiredatwhichpoint
the“0”willturnintoa“*”.
4. Theelevationaxiswilldrivedownontoitsendstop,ifanencoderisinstalleditwillbecalibratedatthispoint,if
notthispositionwillberecognizedaszeroandthesteppermotorwillcounttheincrementsofelevationdrive.
5. Thepolmotorwilldrivetoits“P90”positionatwhichpointtheLNBwillbevertical(ifusingasystemwitha
motorizedpolassembly).
6. Theelevationaxiswillthendriveto45degrees.
7. Oncetheinitializationprocessiscompletetheantennawilltargetthelastpresetsatellite.


Field Service Procedure – Replacement PCU Kit, Coastal

Page2of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

Ifanyofthesestepstakeexcessivetimeordonotcompleteproperly,furtherdiagnosticswillneedtobeundertaken.If
theantennamodelisn’tdisplayedaftertheinitializationprocess,thiswillneedtobepresetinthePCUbeforethe
antennacanoperate.Iftheantennadoesnotcomeoutoftheinitializationprocessitspossibleitcannotseethelast
presetsatellitefromthecurrentGPSlocation,ifthisisthecaseenterintothesetupmenuandverifyifthesettingsare
correct.
5. RateSensorOutputs:
Iftheantennaisn’tstabilizingcorrectlyitcouldbeduetoafaultyratesensor.Atypicalindicationofthisisthatthe
antennawilloperatecorrectlyinstaticconditionssuchasintheport,butwillnotremainonthesatelliteunderdynamic
conditions.
Totesttheratesensorsremovetheradometopandunbolttheradomebasefromitsmountingposition.Nowphysically
rotatethesystemineachaxistoverifyifthemotordrivestheoppositeamountofmovement

1. Totestazimuth:
Rotatetheradomebasearoundthesystemineachdirection,simulatingthevesselsheading
incrementing/decrementing.Theantennashouldremainpointedatthesatellitewithoutlosingthe
signalandgoingintoasearch.
2. Totestelevation:
Tilttheradomebasefromfronttoback,simulatingthevesselpitchingfrombowtoaft.Theantenna
shouldremainpointedatthesatellitewithoutlosingthesignalandgoingintoasearch.
3. Totestthepoldrive(ifapplicable):
Tilttheradomebasefromsidetoside,simulatingthevesselrollingfromstarboardtoport.TheLNB
shouldmoveanequalamounttothemovementexertedonthesystemandshouldremainstable
withoutlosingthesignalandgoingintoasearch.

*Note:TheCoastal18feedassembly(LNB)willrotateleftwhentiltedrightandrightwhentiltedleft.TheCoastal24and
30antennashaveaphasecardinstalledinthefeedhornwhichreversesthepolarityofthelinearsignal,asyourotatethe
antennatotheright,thefeed(LNB)willdrivetotherightandasyourotatetheantennatotheleftthefeed(LNB)will
drivetotheleft.

6. RuntheBuilt‐InTest(BIT):
CoastalPCUsoftware2.06andabovesupportsabuiltintestfunctionusedtoisolateproblemswithcomponentsinthe
antennasystem.ToruntheBITtestpowerofftheantennabypressingthepowerbuttononthecontrolpanel,nowpress
andholdthenextbutton,andthenpressthepowerbutton.Asopposedtoinitializingthecontrolpanelwillnowdisplay
“BuiltInTestNexttoBegin”.
PressingthenextbuttonwillruntheBuilt‐InTestautomaticallyuntilcompleted,ifnofaultsarefoundwiththesystem
“BITFinishedNoErrors”willbedisplayed.Unlessanerrorisdiscoveredthetestwillpausewhilethespecificerroris
highlighted,thisshouldberecordedforfurtherdiagnostics,pressingnextwillcontinuetorunthetest.Anyerrors
recordedrequirefurtherdiagnosticsasperthebelowinformation.


Field Service Procedure – Replacement PCU Kit, Coastal

Page3of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

6.1. AnaloguetoDigitalConvertorTest.
ThistestchecksforbasiccommunicationwiththeAnalogue‐to‐DigitalConverteronthePCUmainboard.A
badA/Dcouldmakeallothertestsfail.
“TestingADC”willbedisplayedasthetestruns.AnErrorcode1.01‐1.08willbedisplayedifoneofthese
testsfails.Ifanytestfails,replacethePCUandre‐runBITtests.
6.2. DigitaltoAnalogueConvertorTest.
ThistestchecksthebasicintegrityoftheDigital‐to‐AnalogueConverteronthePCUmainboardbylooping
backoneofitsoutputstotheD/A.
“TestingDAC”willbedisplayedasthetestruns.AnErrorcode2.01‐2.21willbedisplayedifoneofthese
testsfails.Ifanytestfails,replacethePCUandre‐runBITtests.
6.3. AzimuthMotorDriveTest.
Thistestcheckstheabilityofthemotordrivertodrivecurrentthroughtheazimuthmotor.Thecurrentto
themotoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.
“TestingAZMTR”willbedisplayedasthetestruns.AnErrorcode3.01‐3.17willbedisplayedifoneofthese
testsfails.
Afailureindicatesadefectivemotor,motordriverPCBorharness.Temporarilyconnectasparemotorto
thePCUinplaceofthefailedmotor(orswaptheazimuthmotorwiththepolmotorconnectionatthePCU)
toisolatethefailuretothePCUormotor.Thenrerunthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedtheazimuthandpolmotorconnectionsandthe
polmotortestdidnotfail)andreruntheBITtests.Ifthetestfails,replacethePCUandre‐runtheBITtests.

6.4. ElevationMotorDriveTest.
ThistestcheckstheabilityofthemotordrivertodrivecurrentthroughtheElevationmotor.Thecurrentto
themotoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.
“TestingELMTR”willbedisplayedasthetestruns.AnErrorcode4.01‐4.17willbedisplayedifoneofthese
testsfails.
Afailureindicatesafailedmotor,motordriverPCBorharness.Temporarilyconnectasparemotortothe
PCUinplaceofthefailedmotor(orswaptheelevationmotorwiththeazimuthmotorconnectionatthe
PCU)toisolatethefailuretothePCUormotor.Thenrerunthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedtheelevationandazimuthmotorconnections
andtheazimuthmotortestdidnotfail)andreruntheBITtests.Ifthetestfails,replacethePCUandre‐run
theBITtests.


Field Service Procedure – Replacement PCU Kit, Coastal

Page4of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

6.5. POLMotorDriverTest.
Thistestcheckstheabilityofthemotordrivertodrivecurrentthroughthepolmotor.Thecurrenttothe
motoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.“TestingPOLMTR”willbedisplayedasthetestruns.AnErrorcode5.01‐5.17willbe
displayedifoneofthesetestsfails.
Afailureindicatesafailedmotor,motordriverPCBorharness.Temporarilyconnectasparemotortothe
PCUinplaceofthefailedmotor(orswapthePOLmotorwiththeAZmotorconnectionatthePCU)to
isolatethefailuretothePCUormotor.Thenrerunthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedmotorstheothermotortestwillnotfail)and
reruntheBITtests.Ifthetestfails,replacethePCUandre‐runtheBITtests.
6.6. SensorTest.
Thistestchecksfornullsensoroffsetsforalevel,motionlesssystem.Thecheckshavefairlywidepass/fail
criteria,butcanstillfailifpedestalisinmotionoroutoflevelmorethanafewdegrees.
“TestSensorBias”willbedisplayedasthetestruns.AnErrorcode6.01‐6.05willbedisplayedifoneof
thesetestsfails.Ifanytestfails,replacethePCUandrerunBITtests.
6.7. AzimuthMove/RateSensorTest.
Thistestcommandmovesthedishatvariousspeedsinazimuthandcheckstheresultsusingtheazimutrh
ratesensor.“TestAZSensor”willbedisplayedasthetestruns.AnErrorcode7.01‐7.05willbedisplayedif
oneofthesetestsfails.Anerrorindicatesamotordriverateorsensorfailure.Thiscouldbedueto:
1. Mechanicalbindingofthepedestalortheazimuthbearing‐Withthepoweroff,visuallyinspectthe
antennaandradome(insideofbaseandtop)fordragagainsttheradomeorbinding/foulingofpedestal
intheantennacablesoragainstthecableconnectorbracket.Rotatetheantennainazimuthbyhandto
feelforanybindingintheazimuthaxis.Re‐routecablesand/orbendconnectorbrackettoremove
foulingwiththepedestal.Ifthepedestalisdragginginsidetheradomeitselforiftheazimuthbearing
hasfailed,theradomeand/orpedestalwillhavetobereplaced.Ifthischeckfoundaproblemandyou
havecorrectedit,reruntheBITtests.
2. Azimuthbeltdragging,orslipping‐Inspecttheazimuthdrivebeltforchaffingorwear(leavesblack
dust).Inspecttheazimuthdrivebeltforpropertension(beltshouldbetaughtwhenpinchedinonboth
sidesoftheazimuthmotordrivesprocket,itshouldnotflexmorethan1/16thinchonbothsideswhen
pinched.Re‐alignandtensionthemotorforcorrectbeltpathandtension.Ifthischeckfoundaproblem
andyouhavecorrectedit,reruntheBITtests.
3. Azimuthmotorfailure‐ReplacetheazimuthmotorandreruntheBITtests.
4. Azimuthdriveorazimuthratesensorfailure‐ReplacethePCUandreruntheBITtests.


Field Service Procedure – Replacement PCU Kit, Coastal

Page5of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

6.8. PolPot/MotorMoveTest.
ThistestmovesthefeedassemblyatvariousspeedsinPolarizationandcheckstheresultsusingthePOL
potentiometer.“TestPOLAssy”willbedisplayedasthetestruns.AnErrorcode8.01‐8.07willbedisplayed
ifoneofthesetestsfails.Afailureindicatesafailedmotor,beltorpotentiometer.Thiscouldbedueto:
1. Mechanicalbindingofthepolarizationassembly‐Withtheantennapowereddown,visuallyinspectthe
polarizationassembly(includingLNBandcables)fordragagainstthepedestalordish.Rotatethe
polarizationassemblybyhandtofeelforanybindinginrotation.Re‐routecablestoremovefouling
withthepedestal.Ifbindingisfelt,removemotorbeltandre‐checkbinding.Ifthepolarization
assemblyisstillbinding(indicatingbearingfailure)itmustbereplaced.Ifthischeckfoundaproblem,
andyouhavecorrectedit,re‐runtheBITtests.
2. Poldrivebeltorpolpotdrivebeltdraggingorslipping‐Inspectdrivebeltsforchaffingorwear(leaves
blackdust).Inspectthedrivebeltspropertension(beltsshouldbesemi‐tautwhenpinchedinonboth
sidesofthemotordrivesprocketorpotdrivesprocket.Thebeltsshouldnotflexmorethan1/16thinch
onbothsideswhenpinched).Re‐alignandtensionthemotorandpotforcorrectbeltpathandtension.
Ifthischeckfoundaproblem,andyouhavecorrectedit,re‐runtheBITtests.
3. Rotatethepolarizationassemblytocenterofitsmechanicalrange(LNBvertical)andobservewhileBIT
testruns.Ifthepolmotordoesnotdriveduringthetest,replacethepolmotorandre‐runtheBITtests.
Ifthepolangpotentiometer(polpot)ismountedoutofpositionorhasfailed,rotatethepolarization
assemblytothecenterofitsmechanicalrange.Loosenpotmountingbrackettode‐couplethebeltand
rotatethepotsprocket.Ifthesprocketislooseontheshaftofthepot,tightenthesetscrews.Ifthepot
doesnotrotate,replaceit.
Checkcontinuityofthepotfromthewiperandboththeclockwiseandcounter‐clockwisecontacts.
Clockwisetocounter‐clockwiseendsandviceversa,asteadyresistancefrom0–5or5–0ohmsshouldbe
measured(dependingonthedirectionofrotation)fromwipertoclockwise,orcounter‐clockwise,toverify
properoperation.Thepotisathreeturnpotentiometer,rotatethesprockettofindoneendstopandthen
rotateitexactly1½turnsawayfromthatstoptothecenterofrotation.Holdthesprocketinplacewhile
re‐couplingthebelt,tensionthebeltasyoutightenthepotmountingbracket.Ifthischeckfounda
problem,andyouhavecorrectedit,reruntheBITtests.

Checktheharnessforgoodcontinuityfrompoint‐to‐pointandthattherearenoshortsfromwire‐to‐wire
orfromwire‐to‐groundthatarenotsupposedtobethereaspertheabovediagram.Repairanyharness
problemsfoundandreruntheBITtests.Iftherearenoproblemswithanyofthestepsabove,replacethe
PCUandreruntheBITtests.

Field Service Procedure – Replacement PCU Kit, Coastal

Page6of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

7. ProcedureforReplacingthePCUAssembly:
7.1. Tools.

Snips/Cutters
2mmFlatBlade(Terminal)Screwdriver
#1PhillipsScrewdriver
7/16”Wrench/Spanner
CableTies/TieWraps
Loctite242
7.2. Procedure.
ProcedureforreplacingthePCUassemblyontheCoastalseriesantennas,SeaTelKitpartnumber:135912(PCU
assemblypartnumber:125517‐3).

*Caution:Powerdownthepedestalbeforefollowingthis
procedure.

1.DisconnecttheBNCconnectorfortheGPSantennafrom
thePCU.


2.SnipthecabletiesecuringtheGPSantennacable,coax
cablesandazimuthmotorcabletothePCU.


3.Usinga2mmflatbladescrewdriverundothetwoscrews
securingtheencoderharnesstothePCU.
*Note:TheCoastal18andoldermodelCoastalantennasdo
nothaveanencoderontheelevationmotor.


Field Service Procedure – Replacement PCU Kit, Coastal

Page7of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 


4.Usinga2mmflatbladescrewdriverdisconnectthe
interfaceharnessfromthePCU.


5.Nowusinga#1Phillipsscrewdriverremovethesixscrews
securingtheAZ,ELandPOLmotorconnectionstothePCU.
Becarefulnottolosethe6splitwashersandsavethe
hardwareforfutureuse.


6.Usinga#1Phillipsscrewdriverremovetheforscrews
securingthePCUtothemountingplate.
*Note:DonotremovethePCUatthistimeasthecoax
cablesarestillconnected.


7.RaisethePCUfromthemountingplatetoallowclearance
anddisconnectthetwocoaxcablesfromthePCUusinga
7/16”wench,notingtheorientationoftheRFinandRFout
cables.


8.ApplyLoctite242tothefourholesonthePCUmounting
plate.


Field Service Procedure – Replacement PCU Kit, Coastal

Page8of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 


9.InstallthecoaxcablesontothereplacementPCU,theone
fromtheLNBfeedsintotheRFinport,theRFoutportexits
withtheharnesstothebracketintheradomebase.
*Note:OlderrevisionsoftheCoastalPCUusedasplitterto
splittheRFbetweentheDVBreceiverandbelowdecks.If
replacingoneofthesePCU’swithalaterrevisionthecoax
whichrunsthroughthepedestalwillneedtobeconnectedto
theRFoutportandanothercoaxwillneedtoberunfromthe
LNBtotheRFinport.(SeaTelpartnumber:127963‐30YEL).


10.Reinstallthefourscrewsandwashersthatsecurethe
PCUtoitsmountingbracket.


11.ConnecttheinterfaceharnesstothereplacementPCU.


12.Installthe6screwsandwasherstosecuretheAZ,ELand
POLmotorharnessestothereplacementPCU,noneedto
applyLoctiteassplitwashersareused.




Field Service Procedure – Replacement PCU Kit, Coastal

Page9of9

Document No
135553 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 


13.InstalltheelevationencoderharnesstothePCU.
*Note:IfreplacingthePCUonacoastal18oroldermodel
withnoencoderthisconnectionwillbeleftempty.


14.Securethecoaxcables,azimuthmotorharnessandGPS
antennacabletothetieholderinstalledontopofthePCU
usingacabletie.
15.ReconnecttheGPSantennasBNCconnectortothePCU.


8. SystemConfiguration:

OncethereplacementPCUhasbeeninstalleditwillneedtobeconfiguredtotheworkwiththeantennait’sinstalledon.
Pressandholdthesaveanddownarrowbuttontoenterintothesetupmenu.Pressthedownarrowtoscrollthroughthe
presetstothe“factorysettings”optionandpresstheenterbutton.Scrollthroughtothe“Model”optionandpressthe
enterbutton.Nowusetheupanddownarrowkeystoselectthemodelofantennaandpresstheenterbutton.Holdthe
savebuttontostorethissettinginthePCU.
9. TiltBias:

OncethePCUhasbeenreplaceditslevelreference(tiltbias)willneedtobecalibratedtoalignthesensorswiththe
relevantaxis.LeveloftheantennabyusingalevelbubbleorsimilaronthePCUsothatit’struetohorizon.OncethePCU
islevelopenSeaTelsProgtermsoftwareandselect“CoastalPCUDirect”fromtheCommPortsettings,once
communicationshavebeenestablishedtype“5”onthekeyboardtocalibratethetiltsensorandthenenter“shift+w”(W)
tosavethesettings.Thiswillcalibratetheantennashorizonreference.
